Vesicle dedusting agents for joint compounds

Abstract

A drying-type joint compound can comprise: (a) a primary filler at about 50 weight percent (wt %) to about 98 wt % on a dry basis, wherein the primary filler includes one member selected from the group of calcium carbonate, calcium sulfate dihydrate, and talc, and a mixture thereof; (b) a secondary filler at up to about 25 wt % on a dry basis; (c) a binder at about 1 wt % to about 15 wt % on a dry basis; (d) a polymer thickener at about 0.05 wt % to about 3 wt % on a dry basis; (e) a vesicle dedusting agent at about 0.01 wt % to about 10 wt % on a dry basis, wherein the vesicle dedusting agent comprises vesicles; and (f) an additive up to about 10 wt % o on a dry basis; and (g) water at a ratio of water to dry components of about 1:6 to about 3:1.

What is claimed is: 
     
       1. A joint compound selected from the group consisting of a drying-type joint compound, a setting-type joint compound, and a ready-mixed, setting-type joint compound,
 wherein the drying-type joint compound comprises:
 a primary filler at about 50 weight percent (wt %) to about 98 wt % of the drying-type joint compound on a dry basis, wherein the primary filler comprises one selected from the group consisting of calcium carbonate, calcium sulfate dihydrate, and talc, and a mixture thereof; 
 a secondary filler at up to about 25 wt % of the drying-type joint compound on a dry basis; 
 a binder at about 1 wt % to about 15 wt % of the drying-type joint compound on a dry basis; 
 a polymer thickener at about 0.05 wt % to about 3 wt % of the drying-type joint compound on a dry basis; 
 a vesicle dedusting agent at about 0.01 wt % to about 10 wt % of the drying-type joint compound on a dry basis, wherein the vesicle dedusting agent comprises vesicles; 
 an additive up to about 10 wt % of the drying-type joint compound on a dry basis; and 
 water at a ratio of water to dry components of about 1:6 to about 3:1; 
 
 wherein the setting-type joint compound comprises:
 a calcium sulfate hemihydrate at about 20 weight percent (wt %) to about 99 wt % of the setting-type joint compound on a dry basis; 
 a filler at up to about 30 wt % of the setting-type joint compound on a dry basis; 
 a binder at about 0.5 wt % to about 8 wt % of the setting-type joint compound on a dry basis; 
 a polymer thickener at about 0.05 wt % to about 2 wt % of the setting-type joint compound on a dry basis; 
 a vesicle dedusting agent at about 0.01 wt % to about 10 wt % of the setting-type joint compound on a dry basis, wherein the vesicle dedusting agent comprises vesicles; and 
 an additive up to about 10 wt % of the setting-type joint compound on a dry basis; and 
 
 wherein the ready-mixed, setting-type joint compound comprises:
 a calcium sulfate hemihydrate at about 20 weight percent (wt %) to about 99 wt % of the ready-mixed, setting-type joint compound on a dry basis; 
 a filler at up to about 30 wt % of the ready-mixed, setting-type joint compound on a dry basis; 
 a set retarder at about 0.001 wt % to about 2 wt % of the ready-mixed, setting-type joint compound on a dry basis 
 a binder at up to about 8 wt % of the ready-mixed, setting-type joint compound on a dry basis; 
 a polymer thickener at up to about 2 wt % of the ready-mixed, setting-type joint compound on a dry basis; 
 a vesicle dedusting agent at about 0.01 wt % to about 10 wt % of the ready-mixed, setting-type joint compound on a dry basis, wherein the vesicle dedusting agent comprises vesicles; 
 an additive up to about 10 wt % of the ready-mixed, setting-type joint compound on a dry basis; and 
 water at a ratio of water to dry components of about 1:6 to about 3:1. 
 
 
     
     
       2. The joint compound of  claim 1 , wherein the vesicles comprise unilamellar vesicles. 
     
     
       3. The joint compound of  claim 2 , wherein the unilamellar vesicles have an average hydrodynamic diameter of about 50 nm up to 5000 nm and a polydispersity index of about 0.2 to about 0.5. 
     
     
       4. The joint compound of  claim 2 , wherein the unilamellar vesicles have an average hydrodynamic diameter of about 50 nm up to 500 nm and a polydispersity index of about 0.2 to about 0.5. 
     
     
       5. The joint compound of  claim 1 , wherein the vesicles comprise multilamellar vesicles. 
     
     
       6. The joint compound of  claim 5 , wherein the multilamellar vesicles have an average hydrodynamic diameter of about 100 nm up to 5 microns and a polydispersity index of about 0.2 to about 0.5. 
     
     
       7. The joint compound of  claim 1 , wherein the vesicles comprise lecithin. 
     
     
       8. The joint compound of  claim 1 , wherein the vesicles comprise a polyethylene glycol phospholipid derivative and methoxypoly(ethylene glycol)-phosphatidylethanolamine (mPEG-PE). 
     
     
       9. The joint compound of  claim 8 , wherein a weight percentage on a dry basis of the PEG in the polyethylene glycol phospholipid derivative and the mPEG-PE is cumulatively about 0.1 mol % to about 10 mol % based on a total vesicle composition. 
     
     
       10. The joint compound of  claim 1 , wherein the vesicles comprise polyethylene oxide-block-poly(ε-caprolactone) and/or polyethylene oxide-block-polylactide. 
     
     
       11. The joint compound of  claim 1 , wherein the joint compound is the drying-type joint compound and comprises:
 (a) the primary filler at about 65 wt % to about 93 wt % of the drying-type joint compound on a dry basis, wherein the primary filler is calcium carbonate; 
 (b) the secondary filler about 3 wt % to about 25 wt % of the drying-type joint compound on a dry basis; 
 (c) the binder at about 1 wt % to about 10 wt % of the drying-type joint compound on a dry basis; 
 (d) the polymer thickener at about 0.1 wt % to about 2 wt % of the drying-type joint compound on a dry basis; 
 (e) the vesicle dedusting agent at about 0.1 wt % to about 3 wt % of the drying-type joint compound on a dry basis; 
 (f) the additive about 0.01 wt % to about 10 wt % of the drying-type joint compound on a dry basis; and 
 (g) the water at the ratio of water to dry components of about 1:3 to about 1:1. 
 
     
     
       12. The joint compound of  claim 1 , wherein the joint compound is the drying-type joint compound and comprises:
 (a) the primary filler at about 50 wt % to about 93 wt % of the drying-type joint compound on a dry basis, wherein the primary filler is calcium sulfate dihydrate; 
 (b) the secondary filler about 3 wt % to about 25 wt % of the drying-type joint compound on a dry basis; 
 (c) the binder at about 1 wt % to about 10 wt % of the drying-type joint compound on a dry basis; 
 (d) the polymer thickener at about 0.1 wt % to about 2 wt % of the drying-type joint compound on a dry basis; 
 (e) the vesicle dedusting agent at about 0.1 wt % to about 3 wt % of the drying-type joint compound on a dry basis; and 
 (f) the additive about 0.01 wt % to about 10 wt % of the drying-type joint compound on a dry basis; and 
 (g) the water at the ratio of water to dry components of about 1:3 to about 1:1. 
 
     
     
       13. The joint compound of  claim 1 , wherein the joint compound is the setting-type joint compound and comprises:
 (a) the calcium sulfate hemihydrate at about 60 wt % to about 85 wt % of the setting-type joint compound on a dry basis; 
 (b) the secondary filler about 5 wt % to about 30 wt % of the setting-type joint compound on a dry basis; 
 (c) the binder at about 1 wt % to about 4 wt % of the setting-type joint compound on a dry basis; 
 (d) the polymer thickener at about 0.1 wt % to about 1 wt % of the setting-type joint compound on a dry basis; 
 (e) the vesicle dedusting agent at about 0.1 wt % to about 3 wt % of the setting-type joint compound on a dry basis; and 
 (f) the additive about 0.1 wt % to about 5 wt % of the setting-type joint compound on a dry basis. 
 
     
     
       14. The joint compound of  claim 1 , wherein the joint compound is the ready-mixed, setting-type joint compound and comprises:
 (a) the calcium sulfate hemihydrate at about 60 wt % to about 99 wt % of the ready-mixed, setting-type joint compound on a dry basis; 
 (b) the filler at about 5 wt % to about 30 wt % of the ready-mixed, setting-type joint compound on a dry basis; 
 (c) the set retarder at about 0.1 wt % to about 1 wt % of the ready-mixed, setting-type joint compound on a dry basis 
 (d) the binder at up to about 4 wt % of the ready-mixed, setting-type joint compound on a dry basis; 
 (e) the polymer thickener at about 0.1 wt % to about 2 wt % of the ready-mixed, setting-type joint compound on a dry basis; 
 (f) the vesicle dedusting agent at about 0.1 wt % to about 3 wt % of the ready-mixed, setting-type joint compound on a dry basis, wherein the vesicle dedusting agent comprises vesicles; 
 (g) the additive about 0.1 wt % to about 10 wt % of the ready-mixed, setting-type joint compound on a dry basis; and 
 (h) the water at the ratio of water to dry components of about 1:3 to about 1:1.